PEUGEOT Satelis 500 Workshop Manual
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PEUGEOT Satelis 500 Workshop Manual

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Summary of Contents for PEUGEOT Satelis 500

  • Page 1 Sales division Technical network leadership WORKSHOP MANUAL...
  • Page 2 Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 3: Table Of Contents

    SPECIAL TOOLS ............................14 Standard tools............................15 ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE ................16 Functions of the instrument panel......................16 Initializing the system..........................16 Analog functions (hands) .........................17 Speedometer...........................17 Revolution counter............................17 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 4 Removal of the front shield panel......................36 Removal of the rear shield panel ......................37 Removal of the instrument cluster ......................39 Removal of the dirt shield ........................40 Removal of the battery holder........................40 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 5 Removal of the engine ..........................72 Removal of the fork..........................76 Replacing the steering head cups......................76 Removal of the fork..........................76 Replacing the steering head cups......................76 Steering system tightening method......................79 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 6: Products Danger Symbols Used

    Used batteries collection point People's safety can be seriously affected if Compulsory Operation that can be the recommendations are not fully gloves dangerous for people respected Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 7 Indicate the specific procedures that shall New part Use a new part be followed in order not to damage the vehicle Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 8: Characteristics

    Minimum grade: API GL4. Coolant 1.4 LPeugeot coolant part number 754614 Fork oil 200 cc per tube (Esso Univis 46 or Agip HLift 46) Fuel tank 13.2 L Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Chassis

    Rear tyre pressure 2.4 bars Chassis markings Engine marking 1. Manufacturer's plate. (Left side). 2. Engine number - VIN number of the RH side of the vehicle Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Service Schedule And Commissioning

    Drive pulley bearings and guides #. Transmission belt Belt anti-flapping roller #. Engine oil (+ clean strainer) Engine oil filter Relay box oil Brake fluid and coolant Once every 2 years Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 11: Check And Lubricate

    9100 9300 9400 9600 Time required for maintenance C: Check. N: Clean. R: Change. G: Check and lubricate. * Depending on equipment. # Change if necessary. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 12: Battery Preparation (Except Battery Without Maintenance)

    Check the tyre pressures cold. Check operation of the lights, flashers, horn, and brake light. Check the different warning lights work. Carry out a road test. * Depending on equipment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 13: Special Important Points

    An immobiliser built in the ECU provides the antitheft function by means of a transponder. The ECU has a diagnostic function which via the instrument cluster LED or the diagnostic tool, enables reading of the faults in the memory. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 14: Tightening Torques

    1.1 m.daN Balancing shaft 2.8 m.daN Engine drain plug 2.5 m.daN Water pump cap 0.4 m.daN Water pump impeller 0.5 m.daN Cooling system bleeder screw 0.3 m.daN Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Body Panels

    1 m.daN Nut and bolt 8 mm diameter 2.2 m.daN Nut and bolt 10 mm diameter 3.5 m.daN Nut and bolt 12 mm diameter 5.5 m.daN Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Special Tools

    Steeing head Fuel injector 756017 power supply 758810 installation harness tool 756715 Tank gauge 24 way 758924 spanner terminal block BM 2005 (*) New or modified tool Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Standard Tools

    Type: Facom J.208A50 Automatic resetting type Automatic resetting type torque wrench. torque wrench. 5 to 25 Nm 40 to 200 Nm Type: Facom R.306A25 Type: Facom S.208A200 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Electronic Instrument Functioning Principle

    If this is not the case, switch the ignition off, disconnect and re-connect the battery. After initializing, the low oil, stoplight or ABS, injection diagnosis indicator lights remain on. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Analog Functions (Hands)

    5. Outside temperature gauge. 2. Daily odometer. 6. Engine temperature gauge. 3. Fuel gauge. 7. Battery voltage fault. 4. Digital clock. 8. Maintenance indicator. 9. Empty tank indicator light. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Tripmeter

    When the fuel tank is empty, all segments are off and the pump flashes. Fuel gauge self-diagnostic All segments flash if the fuel gauge or its wiring is faulty. Open circuit (wire cut). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 21: Digital Clock

    16 volts. Maintenance indicator. Maintenance function: The maintenance indicator goes on 5000 kms after the last reset. Maintenance reset: Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Additional Functions

    The ABS/MBS ECU remains powered as long as the vehicle runs, even if the engine stalled. Incident. Revolution counter and speedometer hands are not synchronized when switching the ignition on. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 23 Vehicle with Magneti Marelli system. Temperature sensor circuit not detected. - Check the engine temperature sensor circuit. - Turn off the ignition. - Disconnect and re-connect the battery. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Electricity

    Lambda sensor. 16. Instrument panel. Starter motor switch. 17. Kickstand switch. Starter motor relay. 18. Emergency stop switch. Cooling fan. 19. Engine temperature sensor. 10. Fan relay. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Schematic Diagram Of The Instrument Panel And Of The Lighting

    8. Outside temperature sensor. 18. Hazard warning lights switch. 9. Oil pressure switch. 19. RH direction indicators. 10. Saddle opening contact switch. 20. LH direction indicators. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 26: Abs/Mbs System Schematic Diagram

    9. Starter motor relay. 4. Ignition switch. 10. Injection ECU. 5. Power supply relay. 11. Diagnostic plug. 6. ABS/MBS relay. 12. Instrument panel (diagnostic lamp, machine speed). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Fuses And Energy Distribution

    Lighting relay. Starter motor relay control relay. Instrument panel. Dip switch (main/low headlight). Horn. Number plate light. Sidelight. Stop light contact switch. Saddle opening module (option) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 28 GR-RG F4-15A GR-BE F7-30A Satelis 400/500cc Injection ECU. Transponder antenna. Diagnostic plug. 7.5A Injection relay. ABS diode. Pressure control unit. ABS relay. Power supply relay. ABS. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 29: Location Of Components

    9. Fuel pump. 21. Outside temperature sensor. 10. Fuel gauge. 22. Emergency stop switch. 11. Diagnostic lights. 23. Kickstand switch. 12. Diagnostic plug. 13. Starter motor relay/Fuses. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Body Panels

    14. Rear cover. 6. Tank streamlining. 15. Side panels. 7. Counter panel. 16. Mudflap. 8. Front shield panels. 17. Passenger backseat. 9. Bottom panel. 18. Helmet compartment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Body Component Sequence Of Disassembly

    BODY PANELS Body component sequence of disassembly * This item may be removed on its own. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Removal Of The Rider's Saddle

    - Flip up the seat to the front of the vehicle. - Remove: • The 2 lower pivot clips. • The 2 pivot pins. - Remove the passenger seat. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Removal Of A Rh Or Lh Grab Handle

    - Remove the taillight. (1 screw). - Remove the 4 screws from the taillight unit. - Separate the 2 parts in order to reach the bulbs. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 34: Removal Of A Rh Or Lh Side Cover

    - Push aside the footboard in order to clear the side cover holder eyelet. - Remove the side cover. - Disconnect the taillight. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 35: Removal Of The Storage Compartment

    - Disconnect the plate light and the saddle opening contact switch. - Remove the storage compartment. (4 screws and 2 nuts). When dismantling the splash guard, fit the screws with standard thread lock. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 36: Removal Of The Tank Covers

    - On each side remove: • 8 plastic screws. (1) • 3 washer head screws. Ø6 mm. (2) • 1 washer head screw. Ø5 mm. (3) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 37: Removal Of The Front Top Cover Panel

    Removal of the front top cover panel Procedure 7. - Remove the front top cover panel. (4 screw). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 38: Removal Of The Headlight And Sidelight Assemblies

    • 1 washer head screw. Ø6 mm. (5) • 1 washer head screw. Ø5 mm. (6) A A 5 - Disconnect the headlights. - Remove the front shield panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 39: Removal Of The Rear Shield Panel

    (2) - On each side remove: • 6 plastic screws. (3) • 2 washer head screws. Ø6 mm. (4) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 40 - Remove the header tank. (Right side). - Disconnect the accessory plug. (Left side). - Remove the rear shield panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 41: Removal Of The Instrument Cluster

    - Remove the instrument cluster fairing. Note: When connecting, the lever must be pushed all the way to (A) in order not to damage the connector. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 42: Removal Of The Dirt Shield

    - Unclip from the battery holder: • The fuses. (1) • The relays. (2) • The diagnosis plug.(3) - Remove the battery bracket. (2 screws and 1 nuts). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 43: Service Operations

    - Using a facom D155 type oil filter notched cap wrench, remove the oil filter. Drain the engine when it is warm. Wear gloves in order not to get burnt. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 44: Draining The Relay Box

    Note: Check the level with the machine par- ked on its centre stand, on level ground. Draining the relay box. - Remove the relay box filler cap. (1) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 45: Replacing The Air Filter

    Replacing the air filter - Remove the LH side fairing. See: Procedure 3. Page: 32. - Remove the air filter cover (9 bolts) and its seal. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 46 - Lubricate the air filter with a special oil for air filters and squeeze out the excess oil. - Remove the inlet silencer drain plug to let humidity and oil drip out. (2) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 47: Removal Of The Transmission Air Filter

    - Remove the transmission air filter. (4) - Blow the air filter with compressed air. - Remove the transmission cover. (Refer to the workshop manual: 400/500cc engine. 4 valves. Reference: 759533. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 48: Removal Of The Spark Plug

    - Remove the footboards. See: Procedure 6. Page: 34. - Remove the header tank cap. - Disconnect the water pump and cylinder head hoses. (1 and 2) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 49 - If necessary add coolant in the header tank A. Maximum level. B. Minimum level. Note: Check the level with the machine par- ked on its centre stand, on level ground. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 50: Installing The Valve Clearance

    (A) mark on the pinion with the mark on the cylinder head. Note: With a 500 cc engine equipped with an automatic decompressor valve, use the flywheel magneto mark. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 51 • 15/100 at the intake • 15/100 at the exhaust - Immobilize the rocker set screw. - Tighten the locknut without altering the adjustment. - Check the adjustment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 52: Replacing The Brake Pads

    - Carry out the same operation for the RH side Rear brake. - Remove the exhaust muffler trim. (3 screw) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 53 - Remove the upper fixing bolts. (2) - Remove the exhaust. Tightening torque: 1 m.daN. - Remove the collar retaining pin. (3) - Remove the collar. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 54 (7). Tightening torque: 4.5 m.daN. - Remove the pin, the nut retainer and the wheel nut. (8) Tightening torque: 13.5 m.daN. - Remove the suspension arm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 55 - When refitting the brake pads, push the pistons all the way into their housing. Note: After refitting, actuate the brake levers several times to bring the brake pads against the brake disc. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 56: Checking The Brake Fluid Level

    - Remove the handlebar upper fairing. (8 screw) - Remove the cover and the diaphragm from the master cylinder. (2 screw) - Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 57: Servicing The Abs/Mbs System

    Hold the brake levers at 20 mm from the rest position using plastic straps. This ope- ration allows you to close the circuits and to avoid emptying the hydraulic controls when disconnecting the modulator. Do not remove the master cylinder covers. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 58 Place a pan under the modulator so that the brake fluid will drip into it. The modulator shall not be open, the manufacturer is the only one allowed to service this component. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 59: Re-Installing The Modulator

    Tightening torque: 2.8 m.daN. Note: Change the copper seals each time they are removed. - Connect the modulator. - Bleed the hydraulic system according to the required procedure. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 60: Bleed Procedure

    - Open the bleed screw by 1 to 2 turns. - Inject the brake fluid slowly into the circuit until the level inside the reservoir is halfway - Close the bleeder screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 61 - Otherwise, repeat the operation from the beginning. - Check the brake fluid level and if necessary top up in the master cylinder, and re-fit the master cylinder cover. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 62: Bleeding The Assistance Circuit

    - Stop the operation when there are no more bubbles in the transparent pipe. - Close the bleeder screw. As a precautionary measure, the pump shall not continuously operate for more than 2 minutes. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 63: Draining The Front Brake Circuit

    2 cm (A) maximum from its rest position until no more bubbles can be seen coming up through the master cylinder. - This operation can take a few minutes. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 64 - Stop the operation when no more bubbles are expelled from the modulator. - Close the bleeder screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 65 - Check by actuating the LH control lever: the front wheel stops. - If not, repeat the operation: Bleeding the assistance circuit. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 66: Miscellaneous Operations

    The pressurised jet of fuel may be dangerous for the skin, do not expose the hands to the jet of fuel when opening the injector. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 67: Checking Fuel Pressure

    Before disconnecting the pressure gauges, lower the fuel pressure in the fuel system. Always reinstall the hoses with new hose clamps. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 68: Removal Of The Fuel Pump

    756715 - Remove the tank cover panel. See: Procedure 5. Page: 34. - Disconnect the fuel gauge. - Using tool P/N 756715, remove the fuel gauge. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 69: Removal Of The Throttle Box

    - Remove the inlet coupling 3 fixing bolts. (5) - Remove the 3 screws that secure the throttle box. (6) - Disconnect the throttle control cables. (7) - Remove the throttle box. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 70: Removal Of The Lambda Sensor

    Removal of the regulator - Remove the RH footboard. See: Procedure 6. Page: 34. - Disconnect and remove the regulator. (1) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 71: Removal Of The Radiator

    - Drain the cooling circuit. - Disconnect the 4 hoses of the radiator's cooling circuit. - Remove the radiator. - Remove the fan. (3). (3 screw) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 72: Removal Of The Engine Mounting Assembly

    - Remove the sheath holder. (A) - Loosen the 2 nuts. (2) Tightening torque: 9.5 m.daN. - Remove the 2 nuts from the torque rods. (3) Tightening torque: 3.6 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 73 Note: We recommend greasing all needle bearings when refitting these parts. - When re-installing, fit the rubber bushings with the colours shown: A. Black B. Grey Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 74: Removal Of The Engine

    • The throttle box. (5) • The temperature sensor. (6) • The magneto. (7) • The engine ground. (8) • The suppressor. - Disconnect the injector fuel feed hose. (9) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 75 • The starter motor. (11) - Disconnect the lower pump from the coolant pump to drain the cooling system. - Disconnect the cylinder head hose. (12) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 76 - Re-install the wheel. - Suspend the rear of the machine. - Remove the shock absorber lower mount (14). - Remove the linkrod-to-engine connecting pin. (15) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 77 MISCELLANEOUS OPERATIONS - Lift the rear of the machine. - Disconnect the throttle control cables. (16) - Remove the engine. - Remove the 4 spacers. (17) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 78: Removal Of The Fork

    - Remove the front mudguard. Note: When re-installing, respect the way the speedometer drive cable is rou- ted and the position of the 3 clips. (6) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 79 - Using a drift, remove the steering head cups. - Using a chisel, pry the steering head cup off by pressing the tool behind the dust cover. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 80 • The plain washer. (1) • The dust cover. (2) • The fork cone. (3) - Install new steering head cups using tool P/N 758810. 758810 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 81: Steering System Tightening Method

    - Fit the lock washer (6) in the notches of the locknut and adjustable cone. - Install the steering head locknut and tighten Tightening torque: 7.5 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 82 MISCELLANEOUS OPERATIONS Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 83 MISCELLANEOUS OPERATIONS Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 84 P/N. 759562 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. Printed in the E.U. 10/2007 (non contractual pictures)

This manual is also suitable for:

Satelis 400

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